Flexible cover for boards of a deck structure

ABSTRACT

A cover for boards of a wooden deck structure is made of flexible material and is preferably made from polyvinylchloride. The cover has a central portion with side portions that are integral therewith and can pivot relative to the central portion from a first position that is substantially parallel to the central portion to a second position that is substantially perpendicular to the central portion. The cover can be formed into rolls of significant length and can be installed by cutting an appropriate length from the roll to completely cover a single board from end to end. No adhesives or fastening means are required. A combination of a cover and wooden deck structure, and a method of installation of the cover on a deck structure is also provided. Each board of the deck is covered individually.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a cover for boards of a wooden deck structure where the cover is made of flexible material as a central portion with side portions that are integral therewith and can pivot above the central portion.

2. Description of the Prior Art

Covers for deck boards are known in which a cover installed on each board. However, previous covers suffer from one or more disadvantages. One disadvantage is that previous covers are made from rigid material that has a U-shape and a specific length. These covers are extremely expensive and they have a very high shipping cost because of their fixed shape. These rigid covers also have a specific length, which differs from the length of the deck boards onto which the covers are to be installed. Usually the deck boards are longer than the rigid covers and therefore two or more of the rigid covers must be installed on one deck board resulting in seams being located between adjacent covers. Previous deck boards often are difficult to install because they do not properly fit the deck board. Previous coverings must also be fastened to the deck board and the fastening can result in the covering becoming damaged. Also, when the covering is fastened to the deck boards, the fastening can be difficult to remove when it is desired to remove the deck board. If adhesive is used to attach the covering the deck board can be permanently damaged by removing the covering. The rigid coverings can be uncomfortable for a user to walk on, particularly when the user is barefoot. The Forshee U.S. Pat. No. 4,885,882 describes a rigid U-shaped channel member which fits over one board of a deck structure. Channel members are attached to the board by glue. The Tumball U.S. Pat. No. 4,907,387 describes a rigid channel that is attached to boards of a deck structure applying a bonding material. The Oliveri U.S. Pat. No. 5,794,390 describes a rigid covering for deck boards which are attached to the wood boards by adhesive and other fastenings means and also by screws.

The rigid U-shaped coverings cannot be made to fit over warped deck boards. Since the decking is used outside, it is subjected to high fluctuations in temperature. The wood of the deck boards expands and contracts at a different rate than the rigid covering and the different coefficients of expansion will result in damage to the covering or to the deck boards, or to the deck structure.

The rigid plastic coverings can be very time consuming to install as they often require installation of a number components. Wooden deck structures are often made from pressure treated lumber and that lumber which contains chemicals, can be harmful to humans particularly if splinters from the deck penetrate the skin.

The O'Connor U.S. Pat. No. 5,475,952 describes a floor covering material in the form of a plurality of strips having a fibrous floor covering layer bonded to a plastic layer. The covering layer is attached to the deck plank by staples that are applied through the covering layer. The covering layer has no parts that extend downwardly or covering the side surfaces of the planks.

None of the previous products has achieved even a reasonable level of commercial success. Some previous deck structures are made entirely of plastic material and are many times more expensive than wood structures of similar size.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a deck covering which is available at a reasonable cost so that it will not add greatly to the cost of the wood structure where the deck covering will not be damaged by the expansion and contraction of the wood deck boards, which will provide a cushioned surface to a user, which will protect the user from splinters and injuries from fasteners, is made from a single material, will remain in place without the use of fasteners, will protect both the top and sides of the deck boards from the weathering, has virtually no seams, will not mildew or rot and is simply and easy to install and remove.

A cover for boards of a wooden deck structure comprises an elongated strip having two outer edges that are substantially parallel to one another. The strip is made from flexible material and has two ends with a central portion and two side portions located on either side of the central portion. The side portions are integral with the central portion and the side portions are pivotable relative to the central portion from at least a first position that is substantially parallel to the central portion, to a second position that is substantially perpendicular to the central portion.

A cover and boards of a wooden deck structure in combination, has boards that are made from wood and have a generally rectangular cross-section. The cover comprises an elongated strip having two outer edges that are substantially parallel to one another. The strip is made from flexible material and has two ends with a central portion, and two side portions located on either side of the central portion. The side portions are flexible about the central portion from a first position substantially parallel to the central portion, to a second position substantially perpendicular to the central portion. The cover is sized so that the top portion covers a top of one board, and the side portions extend downwardly on either side of the board. When the boards are adjacent to one another to form a supporting surface of the deck structure, the boards are separated by a gap of sufficient size to receive the two side portions of the strip. There is one side portion for each board in each gap between adjacent boards.

A method of installing a cover on boards of a deck comprises unrolling a sufficient length of the cover from the roll to completely cover a particular deck board from end to end of the deck board, cutting the strip of the cover to an appropriate length, installing the cover on the deck board by pivoting the side portions downward relative to the central portion, and inserting the side portions into a gap on either side of the board with the lower surface of the central portion resting on an upper surface of the board.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a cover;

FIG. 2 is a bottom view of the cover;

FIG. 3 is an end view of the cover of FIGS. 1 and 2;

FIG. 4 is a schematic top view of a cover in the form of a roll;

FIG. 5 is a top view of covers installed on adjacent boards of a deck structure;

FIG. 6 is an end view of the covers and deck structure of FIG. 5;

FIG. 7 is an end view of a cover with side portions extending downward from said central portion; and

FIG. 8 is a further embodiment of a cover having a larger width than the covers shown in FIGS. 1 to 7.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

In FIGS. 1 and 2, a cover 2 has a strip 4 with outer edges 6 and two ends 8. The length of the strip is greatly abbreviated to fit the strip on the paper. The strip 4 has a central portion 10 with side portions 12. There is a boundary 14 extending longitudinally between the central portion 10 and each of the side portions 12. The strip 4 has an upper surface 16 and that portion of the upper surface 16 on the central portion 10 is a rough surface 18. That part of the upper surface 16 on the side portions 12 is smooth. The rough surface 18 is the surface that is walked on when the cover is installed on a deck board (not shown in FIGS. 1 and 2). While the upper surface of that part of the cover on the deck board can be smooth, it is preferable that the surface be roughened in some manner to provide greater friction to a user. The upper surface of the side portions can also be roughened but is preferably smooth to make the side portions easier to install.

In FIG. 2, the strip 4 of the cover 2 has a lower surface 20 with two score lines 22 extending longitudinally along the strip 4 substantially parallel to the outer edges 6 along each side. The score lines 22 are not located directly under the boundaries 14, but are located slightly outside the boundaries 14. The score lines 22 make it easier for the side portions to pivot downward by 90 degrees relative to the central portion 10. Preferably, the score lines 22 are an inverted V-shaped groove, but the score lines can have other suitable shapes, for example, U-shaped.

In FIG. 3, the strip 4 of the cover 2 is shown in an end view. The central portion 10 is thicker at a center than at the boundaries 14, the side portions 12 are thicker than the central portion 10 and the outer edges 6 are tapered to a blunt point 24. The score lines 26 are located just inside the boundaries 14 in the lower surface 20. Boundaries 14 are located in the upper surface 16. The cover 2 shown in FIG. 3 is the actual size of a cover that is used to cover a 2″×4″ board with the central portion 10 located on top of the 2×4 and the side portions 12 extending down the sides of the 2×4. The cover 2 is sized so that the sides cover the sides of the 2×4 (not shown in FIG. 3). The tapered point 24 facilitates the insertion of the sides into the gap (not shown) between the deck boards during installation of the cover.

In FIG. 4, there is shown a schematic top view of the cover 2 formed into a roll with the central portions and side portions (not shown) substantially parallel to each other with one end 8 substantially at a centre of the roll and another end 8 on the circumference of the roll. The roll 26 can be any suitable length and greatly reduces the shipping costs of the cover and makes the cover much easier to store, transport and install. During installation, the user can measure each board and cut the required amount of cover from the roll to install the cover on that particular board. In succession, the user can install the entire roll on a deck without any seams on any particular board. Depending on the size of the deck, the user can have an appropriate number of one hundred foot rolls. While one hundred foot rolls are suggested, rolls having a greater or lesser length of cover than one hundred feet can also be used. The roll should be small enough to be easily carried by a user. The cover is preferably extruded and the score lines and boundaries are formed into the cover as it is extruded. Various materials can be used to make the cover as long as the resulting cover is sufficiently durable and flexible. The remnant of a roll can be discarded or installed on shorter boards, or on boards with two or more covers thereon and a seam between the two covers. A preferred material is polyvinylchloride

In FIGS. 5 and 6, there is shown a top view and end view of a wooden deck structure 28 (only partially shown) having deck boards 30 thereon spaced apart by a gap 32. There are six deck boards 30 and five gaps 32 located between these six deck boards. The six deck boards each have a cover 2 installed thereon with the central portion 10 located on top of each board 30 and the side portions 12 extending down the two sides of each board. In FIG. 5, only the rough surface 18 of the cover 2 can be seen. In FIG. 6, the central portion 10 and the side portions 12 can be seen for each of the six covers.

In FIG. 7, there is shown an end view of a cover 34 shaped as though it is installed on a deck board. However, the deck board has been omitted so that the cover 34 can be more easily viewed. The cover 34 differs from the cover 2 in that the cover 34 has two extra score lines 36 that are located in the upper surface 16.

In FIG. 8, there is shown an end view of a further embodiment of a cover 38 that is much wider than the covers 2, 34. The cover 38 is sized to be installed on a 2″×6″ board (not shown) with straight sides or by a 2″×6″ deck board (not shown) with rounded sides. The cover 38 has two boundaries 40 located between the central portion 10 and the side portions 12 and two score lines 42, 44 in the lower surface 20 on each side. The score lines in the upper surface preferably have the same shape as the score lines in the lower surface, but the score lines can also have different shapes. The cover can be manufactured and sized to fit boards of various sizes including 2″×8″ and 2″×10″ as well as metric sizes.

While fasteners or fastening means can be used with the cover of the present invention, fasteners are not required to be used unless, perhaps, very small pieces of the cover are being installed. When used to cover a deck board, when the cover is installed with the side portions inserted at each side of the deck board and the central portion on top of the deck board, the weight of the cover is usually more than sufficient to hold the cover in position on the deck board without any fasteners or fastening means. Also, the vertical side portions assist in holding the cover in position as the side portions resist forces that tend to bend or curve the central portion upward.

Since the cover is extruded in one piece, any reasonable length of cover can be extruded. For example, rolls having a length of 50, 75 or 100 feet are suitable. Preferably, rolls have a length of at least 50 feet. The cover provides a resilient cushion on the deck boards, thereby providing greater comfort to a user, as well as protection from slivers and injury. The cover also protects the deck boards. Therefore, less expensive wood can be used than would be desirable without the cover on each of the boards as the cover protects the deck boards. For example, relatively inexpensive non-pressure treated wood can be used. Alternatively, pressure treated wood or even cedar can be used and the cover will greatly extend the life of the wood. 

1. A cover for boards of a wooden deck structure, said cover comprising an elongated strip having two outer edges that are substantially parallel to one another, said strip being, made from flexible material, said strip having two ends with a central portion and two side portions located on either side of said central portion, said side portions being integral with said central portion, said side portions being pivotable relative to said central portion from at least a first position that is substantially parallel to said central portion to a second position that is substantially perpendicular to said central portion.
 2. A cover as claimed in claim 1 wherein said cover is sufficiently flexible to be formed into a roll with one end of said cover substantially at a center of said roll and another end being located on a circumference of said roll.
 3. A cover as claimed in claim 2 wherein said side portions extend outward substantially parallel to said central portion in said roll.
 4. A cover as claimed in claim 1 wherein said cover is made from extruded material.
 5. A cover as claimed in claim 4 wherein there are longitudinal score lines to reduce a thickness of said cover in an area where said side portions pivot about said central portion.
 6. A cover as claimed in claim 5 wherein there are two of said score lines along each side of said cover, one of said score lines being in an upper surface of said cover and another of said score lines being in a lower surface of said cover.
 7. A cover as claimed in claim 6, wherein there is one additional score line along each side of said cover, the additional score line being located in said lower surface of said cover.
 8. A cover as claimed in claim 1 wherein said central portion is sized to fit on top of a single board on a deck, said side portions extending downward on either side of said single board in a gap between adjacent boards.
 9. A cover as claimed in claim 8 wherein there are no adhesives or fastening means located between said cover and said board on which the cover is installed.
 10. A cover as claimed in claim 1 wherein there are fastening means located between said cover and said board.
 11. A cover as claimed in claim 1 wherein said cover is made from polyvinylchloride.
 12. A cover as claimed in claim 3 wherein said roll has a length of at least 50 feet.
 13. A cover as claimed in claim 5 wherein said central portion is slightly thicker at a center thereof and thinner near said side portions, and said side portions are thicker than said central portion, said score lines being notches extending between said ends of said cover.
 14. A cover and boards of a wooden deck structure in combination, said boards being made from wood and having a generally rectangular cross-section, said cover comprising an elongated strip having two outer edges that are substantially parallel to one another, said strip being made from flexible material, said strip having two ends with a central portion and two side portions located on either side of said central portion, said side portions being pivotable about said central portion from a first position substantially parallel to said central portion to a second position substantially perpendicular to said central portion, said cover being sized so that said top portion covers a top of one board and said side portions extend downward on either side of said board, when said boards are adjacent to one another to form a supporting surface of said deck structure, said boards being separated by a gap of sufficient size to receive the two side portions of said strip, there being one side portion for each board in each gap between adjacent boards.
 15. A combination as claimed in claim 14 wherein said cover is made from extruded material and there are longitudinal score lines to reduce a thickness of said cover in an area where said side portions pivot about said central portion.
 16. A combination as claimed in claim 15 wherein there are two of said score lines along each side of said cover, one of said score lines being in an upper surface of said cover and another of said score lines being in a lower surface of said cover.
 17. A combination as claimed in claim 16 wherein there is one additional score line along each side of said cover, the additional score line being located in said lower surface of said cover.
 18. A combination as claimed in claim 14 wherein said central portion is sized to fit on top of a single board on a deck, said side portions extending downward on either side of said single board in a gap between adjacent boards.
 19. A combination as claimed in claim 18 wherein there are no adhesives or fastening means located between said cover and said board on which said cover is installed.
 20. A combination as claimed in claim 14 wherein said cover is made from polyvinyl chloride.
 21. A combination as claimed in claim 15 wherein said central portion is slightly thicker at a center thereof and thinner near said side portions, said side portions being thicker than said central portion and said score lines being notches extending between said ends of said cover.
 22. A method of installing a cover on boards of a deck, said cover having an elongated strip having two outer edges that are substantially parallel to one another, said strip being made from flexible material, said strip having two ends with a center portion and two side portions located on either side of said central portion, said side portions being integral with said central portion, said side portions being pivotable relative to said central portion from at least a first position that is substantially parallel to said central portion, to a second position that is substantially perpendicular to said central portion, said cover being formed into a roll with one end of said cover substantially at a center of said roll, and another end of said cover being located on a circumference of said roll, said method comprising unrolling a sufficient length of said cover from said roll to completely cover a particular deck board from end to end of said deck board, cutting the strip of said cover to an appropriate length, installing the cover on said deck board by pivoting the side portions downward relative to the central portion and inserting the side portions into the gap on either side of said board with the lower surface of the central portion resting on an upper surface of said board. 